Stretch Knit Appliqué Structure for Crack-Resistant Elastic Bonding
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Solution Overview
Problem
Current methods fail to produce textile appliqués with elastic properties that match those of stretchable and elastic materials, as the adhesive layer tends to crack or split when stressed, leading to detachment and loss of aesthetic and functional qualities.
Innovation Solution
A method involving a sublimation dye heat transfer applied to knitted textile appliqué media, followed by an elastomeric adhesive layer with a specific structure, including a first and second thermoplastic adhesive film and an elastomeric film, ensuring the appliqué's elasticity and recovery, preventing penetration of adhesives into the textile or article, and maintaining mechanical grip.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a standard adhesive layer is used to bind the textile appliqué to the elastic article, then the appliqué can be attached to the article, but the adhesive layer cracks and splits when stretched, causing detachment and loss of aesthetic quality
Solution Approach 1:
The patent changes the physical and chemical parameters of the adhesive layer by incorporating elastomeric materials and adjusting the adhesive composition to match the elastic properties of the underlying fabric. This allows the adhesive to stretch and recover without cracking, maintaining both bond strength and integrity under stress.
Solution Approach 2:
The adhesive layer is constructed as a composite material system that combines elastomeric polymers with adhesive agents. This composite structure provides both the flexibility needed to match fabric elasticity and the bonding strength required for secure attachment, preventing both detachment and cracking.
2Reliability
If the adhesive layer is made more elastic to match the stretchable apparel, then the adhesive can recover after stretching, but the adhesive layer may detach from the textile appliqué or article
Solution Approach 1:
The adhesive parameters are precisely tuned to achieve optimal elasticity that matches the fabric's stretch characteristics. The elastomeric content and adhesive formulation are adjusted so the adhesive layer can recover after stretching while maintaining sufficient bond strength to prevent detachment.
Solution Approach 2:
The adhesive layer is designed to have homogeneous elastic properties that closely match the underlying fabric. This homogeneity ensures uniform stress distribution during stretching and recovery, preventing both detachment and cracking while maintaining reliable bond strength throughout the entire adhesive area.
3Reliability
If the adhesive layer is made thicker to prevent cracking, then the adhesive may not crack under stress, but the adhesive layer becomes bulky and distorts the appliqué shape
Solution Approach 1:
Rather than increasing thickness, the patent changes the material parameters of the adhesive layer by incorporating elastomeric materials. This allows a thin adhesive layer to achieve crack resistance through enhanced flexibility and elasticity, maintaining the appliqué's dimensional stability and aesthetic appearance without bulk.
4Shape
If the adhesive layer is made thinner to maintain appliqué shape, then the appliqué remains dimensionally stable, but the adhesive layer cracks and splits when stretched
Solution Approach 1:
The patent resolves this contradiction by changing the material composition parameters of the thin adhesive layer to include elastomeric materials. This enables the thin layer to maintain both dimensional stability for shape preservation and enhanced flexibility for crack resistance during stretching and recovery.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution allows for appliqués that remain firmly attached to elastic fabrics, maintaining their shape and elasticity, preventing curling or detachment, and providing a high-quality, dimensionally stable embellishment with enhanced elastic properties.
Implementation Method 1
applying, at a sublimation temperature, a sublimation dye heat transfer image to appliqué media
Implementation Method 2
applying, at a sublimation temperature, a sublimation dye heat transfer image
Implementation Method 3
adhering, typically after the sublimation dye transfer applying step, an elastomeric adhesive layer to the sublimation printed appliqué media
Data Source
AI summary
A stretchable knit appliqué is described. The appliqué is configured by a knitted textile material adhered to an elastomeric film by a first adhesive continuously distributed over elastomeric film. Moreover, the appliqué is configured to stretch with the elastomeric film. The appliqué can have a first and second knitted materials, with a printed design in registration with the first and second textile materials. The printed design can be a sublimation printed design.